Damage mechanics characterization of transverse cracking behavior in quasi-isotropic CFRP laminates with interlaminar-toughened layers

Microscopic damage behavior in quasi-isotropic CFRP laminates with interlaminar-toughened layers under tensile fatigue loading is investigated. Damage observation is conducted using an optical microscope and soft X-ray radiography. The material used is CFRP with interlaminar-toughened layers, T800H/3900-2. The laminate configurations are quasi-isotropic [45/0/−45/90]_s, [0/45/−45/90]_s and [45/−45/0/90]_s to discuss the effect of stacking sequence on microscopic fatigue damages. A damage mechanics analysis is used to obtain the energy release rate for transverse cracking which is correlated to the transverse crack density growth rate. The modified Paris-law analysis proves to be valid for characterization of transverse crack multiplication when the effect of other damage is small.     

Experimental and analytical characterization of transverse cracking behavior in carbon/bismaleimide cross-ply laminates under mechanical fatigue loading

Transverse cracking behavior in high temperature bismaleimide-based carbon fiber reinforced plastics (CFRP) laminates under fatigue loading was observed. Three types of cross-ply laminate, [0/90₂/0], [0₂/90₃/0₂] and [0₂/90₄/0₂], were tested to study the effect of ply thickness. Damage observation was conducted using two methods. Optical microscopy and soft X-ray radiography were used for edge and internal damage observation, respectively. Variational approach was used to derive the energy release rate associated with transverse cracking. Multiplication of transverse cracks was modeled based on modified Paris-law approach.     

[±θ/902]碳/环氧层板横向裂缝与分层的测试及分析

本工作对[±θ/90₂]_S和[0_n/90₂]_S两系列碳/环氧层板在拉仲载荷下的横向裂缝与分层损伤,进行了实验研究和有限元分析.采用声发射技术跟踪配合显微观测多向层板损伤过程,分析了θ角变化与力学性能、初始损伤、累积等的关系.表明实测横向开裂与分层结果和采用能量判据有限元计算预测比较,符合良好.同时在扫描电镜内进行各类层板压缩试验,动态观测破坏形貌,讨论了不同θ铺层角的微观破坏机理.     

Modeling of tensile fatigue damage in resin transfer molded woven carbon fabric composites

Tension–tension fatigue tests were performed on fabric-based composites processed using resin transfer molding. The composite systems consisted of epoxy and phenolic matrices reinforced with plain weave carbon fabric. The residual strength of open-hole laminates was also investigated for various numbers of fatigue cycles. The results based on the fatigue tests and microscopic observations suggested that considerable damage growth occurred in the early stages of fatigue. In order to examine the property deterioration of the laminates due to the fatigue damage, low frequency cyclic loading tests were carried out, while modulus measurements were performed in situ. Quantitative data were obtained, displaying the reduction in modulus for each material system. Finally, a model to predict the modulus deterioration based on a combination of the crimp model and the shear-lag model was developed. Good agreement between the predictions and the experimental results supported the model, which showed the quantitative effects of transverse cracking and debonding between the yarns on the laminate modulus.     

Modelling off-axis ply matrix cracking in continuous fibre-reinforced polymer matrix composite laminates

The fracture process of composite laminates subjected to static or fatigue tensile loading involves sequential accumulation of intra- and interlaminar damage, in the form of transverse cracking, splitting and delamination, prior to catastrophic failure. Matrix cracking parallel to the fibres in the off-axis plies is the first damage mode observed. Since a damaged lamina within the laminate retains certain amount of its load-carrying capacity, it is important to predict accurately the stiffness properties of the laminate as a function of damage as well as progression of damage with the strain state. In this paper, theoretical modelling of matrix cracking in the off-axis plies of unbalanced symmetric composite laminates subjected to in-plane tensile loading is presented and discussed. A 2-D shear-lag analysis is used to determine ply stresses in a representative segment and the equivalent laminate concept is applied to derive expressions for Mode I, Mode II and the total strain energy release rate associated with off-axis ply cracking. Dependence of the degraded stiffness properties and strain energy release rates on the crack density and ply orientation angle is examined for glass/epoxy laminates. Suitability of a mixed mode fracture criterion to predict the cracking onset strain is also discussed.     

Prediction for progression of transverse cracking in CFRP cross-ply laminates using Monte Carlo method

This study predicted transverse cracking progression in laminates including 90° plies. The refined stress field (RSF) model, which takes into account thermal residual strain for plies including transverse cracks is formulated, and the energy release rate associated with transverse cracking is calculated using this model. For comparison, the energy release rate based on the continuum damage mechanics (CDM) model is formulated. Next, transverse cracking progression in CFRP cross-ply laminates including 90° plies is predicted based on both stress and energy criteria using the Monte Carlo method. The results indicated that the RSF model and the CDM model proposed in this study can predict the experiment results for the relationship between transverse crack density and ply strain in 90° ply. The models presented in this paper can be applied to an arbitrary laminate including 90° plies.     

Structural composites hybridized with epoxy compatible polymer/MWCNT nanofibrous interlayers

Surface reactive P(St-co-GMA) copolymer and P(St-co-GMA)/MWCNT fibrous mats are placed onto a conventional carbon fiber/epoxy prepreg as interlayer reinforcing material. Experimental observations are used to demonstrate excellent epoxy wetting and structural compatibility of the interlayers chemically tuned for the epoxy matrix. Comparisons of increase in mechanical performance by incorporating P(St-co-GMA) and P(St-co-GMA)/MWCNT interlayers also show the contribution of MWCNT presence in the copolymer nanofibers. Flexural strength and stiffness of (0/0/0) and (90/0/90) laminates increase up to 17% when the nanocomposite interlayers are integrated. Cross-sectional SEM analyses of the failure surfaces suggest reinforcing ability of interlayers both against transverse cracking and delamination. Further examination for the delamination resistance is presented by the End Notched Flexure (ENF) tests. An improvement up to 70% in mode II strain energy release rate (G_IIc) is recorded for the laminates with nanocomposite interlayers. The resistance against transverse matrix cracking in the presence of interlayers is also elaborated. Charpy-impact and transverse-tension tests result in up to 20% and 27% increase in the impact energy absorbance and transverse tensile strength, respectively. Overall, the test results suggest that mechanical behavior of the laminates is enhanced by the nanofibrous interlayers chemically-tuned for epoxy crosslinking, with no weight penalty.     

Microstructure effects on transverse cracking in composite laminae by DEM

A particle discrete element method (DEM) was employed to simulate transverse cracking in laminated fiber reinforced composites. The microstructure of the laminates was modeled by a DEM model using different mechanical constitutive laws and materials parameters for different constituents, i.e. fiber, matrix and fiber/matrix interface. Rectangular, hexagonal and random fiber distributions were simulated to study the effect of fiber distribution on the transverse cracking. The initiation and dynamic propagation of transverse cracking and interfacial debonding were all captured by the DEM simulation, which showed similar patterns to those observed from experiments. The effect of fiber volume fraction was also studied for laminae with randomly distributed fibers. It was found that the distribution and volume fraction of fibers affected not only the transverse cracking path, but also the behavior of matrix plastic deformation and fiber/matrix interface yielding in the material.     

Transverse crack growth behavior considering free-edge effect in quasi-isotropic CFRP laminates under high-cycle fatigue loading

The high-cycle fatigue characteristics focused on the behavior of the transverse crack growth up to 10⁸ cycles were investigated using quasi-isotropic carbon fiber reinforced plastic (CFRP) laminates whose stacking sequence was [−45/0/45/90]_s. To assess the fatigue behavior in the high-cycle region, fatigue tests were conducted at a frequency of 100 Hz in addition to 5 Hz. In this study, to evaluate quantitative characteristics of the transverse crack growth in the high-cycle region, the energy release rate considering the free-edge effect was calculated. Transverse crack growth behavior was evaluated based on a modified Paris law approach. The results revealed that transverse crack growth was delayed under the test conditions of the applied stress level of σ_max/σ_b = 0.2.     

Cryogenic delamination growth in woven glass/epoxy composite laminates under mixed-mode I/II fatigue loading

This paper investigates the fatigue delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode I/II conditions at cryogenic temperatures. Fatigue delamination tests were performed with the mixed-mode bending (MMB) test apparatus at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), in order to obtain the delamination growth rate as a function of the range of the energy release rate, and the dependence of the delamination growth behavior on the temperature and the mixed-mode ratio of mode I and mode II was examined. The energy release rate was evaluated using three-dimensional finite element analysis. The fractographic examinations by scanning electron microscopy (SEM) were also carried out to assess the mixed-mode fatigue delamination growth mechanisms in the woven GFRP laminates at cryogenic temperatures.     

Application of infrared thermography for the characterization of damage in braided carbon fiber reinforced polymer matrix composites

The focus of this study is to assess, using infrared thermography, the fatigue behavior and the corresponding damage states of a textile polymeric composite plate, as a prerequisite step in the development of damage based life prediction models for such advanced composite materials. Monotonic (quasi-static) loading test results confirmed that the dominant damage mechanism is cracking in the braider yarns, which was monitored using thermographic images and confirmed by edge replication microscopic observations. Fatigue results confirmed that the saturation of braider yarn cracks during cyclic loading corresponded to changes in the stiffness degradation rate as well as the surface temperature profile. This was confirmed by edge replication and scanning electron microscopic analysis. The reported results and observations provide an important step in the validation of thermography as a powerful non-destructive evaluation tool for monitoring the development of fatigue damage as well as predicting the damage states of laminated composite materials in general, and braided polymeric composite materials in particular.     

The influence of hygrothermal conditions on the damage processes in quasi-isotropic carbon/epoxy laminates

The effects of hygrothermal conditions on damage development in quasi-isotropic carbon-fiber/epoxy laminates are described. First, monotonic and loading/unloading tensile tests were conducted on dry and wet specimens at ambient and high temperatures to compare the stress/strain response and damage development. The changes in the Young's modulus and Poisson's ratio were obtained experimentally from the monotonic tensile tests. The critical stresses for transverse cracking and delamination for the above three conditions are compared. The delamination area is measured by using scanning acoustic microscopy (SAM) at various loads to discuss the effects of delamination on the nonlinear stress/strain behavior. Next, the stress distributions under tensile load including hygrothermal residual stresses are computed by a finite-element code and their effects on damage initiation are discussed. Finally, a simple model for the prediction of the Young's modulus of a delaminated specimen is proposed. It is found that moisture increases the critical stresses for transverse cracking and delamination by reducing the residual stresses while high temperature decreases the critical stresses in spite of relaxation of the residual stresses. The results of the finite-element analysis provide some explanations for the onset of transverse cracking and delamination. The Young's modulus predicted by the present model agrees with experimental results better than that predicted by conventional models.     

Prediction of initiation of transverse cracks in cross-ply CFRP laminates under fatigue loading by fatigue properties of unidirectional CFRP in 90° direction

A fatigue life to the initiation of transverse cracks in cross-ply carbon fiber-reinforced plastic (CFRP) laminates has been predicted using properties of the fatigue strength of unidirectional CFRP in the 90° direction. In the experiments, unidirectional [90]₁₂ laminates were used to obtain a plot of maximum stress versus number of cycles to breaking, and two types of cross-ply laminates of [0/90₄]_S and [0/90₆]_S were used to evaluate the initiation and multiplication of transverse cracks under fatigue loading. Transverse cracks were studied by optical microscopy and soft X-ray photography. Analytical and experimental results showed good agreement, and the fatigue life for transverse crack initiation in cross-ply laminates was predicted successfully from the fatigue strength properties of the unidirectional CFRP in the 90° direction. The prediction results showed a conservative fatigue life than the experimental results.     

Accelerated testing for long-term fatigue strength of various FRP laminates for marine use

The prediction of long-term fatigue life of various FRP laminates combined with resins, fibers and fabrics for marine use under temperature and water environments were performed by our developed accelerated testing methodology based on the time–temperature superposition principle (TTSP). The five kinds of FRP laminates were prepared under three water absorption conditions of Dry, Wet and Wet + Dry after molding. The three-point bending constant strain rate (CSR) and fatigue tests for these FRP laminates at three conditions of water absorption were carried out at various temperatures and loading rates. As results, the mater curves of fatigue strength as well as CSR strength for these FRP laminates at three water absorption conditions are constructed by using the test data based on TTSP. It is possible to predict the long-term fatigue life for these FRP laminates under an arbitrary temperature and water absorption conditions by using the master curves. The characteristics of time, temperature and water absorption dependencies of flexural CSR and fatigue strengths of these FRP laminates are clarified.     

Fatigue damage mechanisms and residual properties of graphite/epoxy laminates

Damage mechanisms and accumulation, and associated stiffness and residual strength reductions were studied in cross-ply graphite/epoxy laminates under cyclic tensile loading. Stress-life data were fitted by a two-parameter wearout model and by a second-degree polynomial on a log-log scale. The fatigue sensitivity is highest for the unidirectional laminates and it decreases for the crossply laminates with increasing number of contiguous 90° plies. Five different damage mechanisms were observed: transverse matrix cracking, dispersed longitudinal cracking, localized longitudinal cracking, delaminations along transverse cracks, and local delaminations at the intersection of longitudinal and transverse cracks. Failure patterns vary with cyclic stress level and number of cycles to failure. Under monotonie loading, failure is brittle-like and concentrated. At high stress amplitudes and short fatigue lives failure results from few localized flaws, whereas at lower stress amplitudes and longer fatigue lives failure results from more dispersed flaws. The residual modulus shows a sharp reduction initially, followed by a more gradual decrease up to failure. The residual strength showed a sharp reduction initially, followed by a plateau or even some increase in the middle part of the fatigue life, and a rapid decrease in the last part of the fatigue life. A tentative cumulative damage model is proposed based on residual strength and the concept of equal damage curves.     

Experimental characterization of microscopic damage behavior in carbon/bismaleimide composite—effects of temperature and laminate configuration

Microscopic damage behavior of high temperature CFRP, carbon/BMI (bismaleimide) under tensile loading was investigated experimentally. To clarify effects of laminate configuration and temperature on the microscopic damage behavior, 10 kinds of laminate configurations were tested at both 25 and 180 °C. Damage initiation at the free edge and progress in the width direction were observed using optical microscopy and soft X-ray radiography, respectively. Damage mechanics analysis was used to predict matrix cracking in 90° plies based on both the energy and average stress criteria. It is clarified that the critical energy release rate and critical average stress associated with matrix cracking in BMI based CFRP are larger than in epoxy-based CFRP, which certify the high crack resistance of carbon/BMI composites.     

Influence of load ratio on the biaxial fatigue behaviour and damage evolution in glass/epoxy tubes under tension–torsion loading

An extensive experimental campaign was carried out to understand the influence of the multiaxial stress state and load ratio on the matrix-dominated damage initiation and evolution in composite laminates under fatigue. Tubular glass/epoxy specimens were tested under combined tension–torsion loadings with different values of the load ratio and biaxiality ratio (shear to transverse stress ratio). Results are reported in terms of S–N curves for the first crack initiation and Paris-like diagrams for crack propagation, showing a strong influence of both parameters. Fracture surfaces were also analysed to identify the damage mechanisms at the microscopic scale responsible for the initiation and propagation of transverse cracks. Eventually, a crack initiation criterion presented by the authors in a previous work is applied to the experimental data showing a good agreement.     

Evaluation of impact damage mechanism of multi-axial stitched CFRP laminate

This study focuses on multi-axial stitched fabric, which is a thick, high performance reinforcement for large-scale composite structures. The effects of impact damage on multi-axial stitched CFRP laminates molded by vacuum-assisted resin transfer molding (VARTM) method were evaluated. Impact damage within material was evaluated by ultrasonic scanning device and optical cross-sectional observations. Probed images obtained by both non-destructive and destructive methods were compared, and internal damage distributions of multi-axial stitched CFRP laminates were clarified. In addition, residual compressive strength and fatigue property of impact-damaged CFRP laminates were evaluated by in situ damage growth monitoring using the thermo-elastic stress analyzer (TESA). Three-dimensional damage distribution of impacted CFRP laminate was obtained from ultrasonic C-scan images and cross-sectional photographs. Damage progress behavior was observed on a destructive and non-destructive basis by post-impact fatigue (PIF) test.     

Quantification of flexural fatigue life and 3D damage in carbon fibre reinforced polymer laminates

Carbon fibre reinforced polymer (CFRP) laminated composites have become attractive in the application of wind turbine blade structures. The cyclic load in the blades necessitates the investigation on the flexural fatigue behaviour of CFRP laminates. In this study, the flexural fatigue life of the [+45/−45/0]_2s CFRP laminates was determined and then analysed statistically. X-ray microtomography was conducted to quantitatively characterise the 3D fatigue damage. It was found that the fatigue life data can be well represented by the two-parameter Weibull distribution; the life can be reliably predicted as a function of applied deflections by the combined Weibull and Sigmodal models. The delamination at the interfaces in the 1st ply group is the major failure mode for the flexural fatigue damage in the CFRP laminate. The calculated delamination area is larger at the interfaces adjacent to the 0 ply. The delamination propagation mechanism is primarily matrix/fibre debonding and secondarily matrix cracking.     

Modeling damage and load redistribution in composites under tension–tension fatigue loading

A fatigue model developed for composite laminates and based on the cycle-by-cycle probability of failure has been modified to account for damage creation and evolution and its effect on cycles to failure. The residual strength of different parts of the laminate is determined during cyclic loading and damage such as matrix cracking is quantified along with its effect on load redistribution and cycles to failure of different parts of the laminate. The model does not require any curve fitting or experimentally measured data other than basic material static strength values and their associated experimental scatter. The model is applied to uni-directional and cross-ply laminates. A stress-based approach using energy minimization and calculus of variations is used. The model predictions range from fair to excellent.